Mistake Proofing and Error Proofing in Manufacturing

Human error remains one of the most common causes of defects on South African production lines, yet many corrective actions rely on retraining operators rather than changing the process itself. This course introduces poka yoke and error proofing principles, teaching participants how to design simple mechanical, visual, and procedural safeguards that make it difficult or impossible for a defect to occur or pass undetected.

What you will be able to do

Explain why mistake proofing is more reliable than retraining or warning signs alone.
Identify process steps where human error is most likely to cause a defect.
Classify mistake proofing devices as prevention type or detection type controls.
Design a simple low cost poka yoke device for a specific process step.
Evaluate proposed mistake proofing solutions for cost, reliability, and ease of use.
Build mistake proofing into new process and equipment designs from the outset.

Course outline

01Why Human Error Happens
02Prevention Versus Detection Devices
03Finding High Risk Process Steps
04Low Cost Mechanical Safeguards
05Visual and Sensor Based Controls
06Testing a Poka Yoke Device
07Evaluating Cost and Reliability
08Designing Error Proofing Into New Processes

Who should attend

This course is designed for process engineers, production supervisors, maintenance technicians, and quality improvement teams working on defect reduction.

Dates, venues and fees

Dates	Venue	Days	Fee
17 to 18 Aug 2026	Online	2	US$900
24 to 25 Aug 2026	Mozambique	2	US$1,100
31 Aug to 1 Sep 2026	Cairo	2	US$1,100
7 to 8 Sep 2026	Accra	2	US$1,100
14 to 15 Sep 2026	Lusaka	2	US$1,100
21 to 22 Sep 2026	Kigali	2	US$1,100
28 to 29 Sep 2026	Nairobi	2	US$1,100
5 to 6 Oct 2026	Durban	2	R10,000
12 to 13 Oct 2026	Johannesburg	2	R10,000
26 to 27 Oct 2026	Mauritius	2	US$1,100
2 to 3 Nov 2026	Dubai	2	US$1,100
9 to 10 Nov 2026	Lagos	2	US$1,100
16 to 17 Nov 2026	Harare	2	US$1,100
23 to 24 Nov 2026	Kampala	2	US$1,100
30 Nov to 1 Dec 2026	Dar es Salaam	2	US$1,100
7 to 8 Dec 2026	Pretoria	2	R10,000
14 to 15 Dec 2026	Cape Town	2	R10,000

Fees are per delegate. South African venues are priced in rand; other locations and online in US dollars. Fees exclude 15% VAT where applicable. Group bookings of three or more delegates from the same organisation qualify for a reduced rate; contact us for a quotation.

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Training a whole team?

We can run Mistake Proofing and Error Proofing in Manufacturing privately for your team, on your dates and built around your own systems. Group delivery is usually more cost effective from about six delegates.

Run this in-house